U.S. patent application number 10/363999 was filed with the patent office on 2004-01-15 for mortarless wall structure.
Invention is credited to Price, Gerald P, Price, Raymond R.
Application Number | 20040006945 10/363999 |
Document ID | / |
Family ID | 30115468 |
Filed Date | 2004-01-15 |
United States Patent
Application |
20040006945 |
Kind Code |
A1 |
Price, Raymond R ; et
al. |
January 15, 2004 |
Mortarless wall structure
Abstract
A wall structure (10, 110) and method of construction. The wall
structure (10, 110) comprises a plurality of preformed, lightweight
blocks (12, 112) supported and interconnected by a plurality of
elongated, vertically oriented, collateral support beams (16, 116).
Preferably, the support beams (16, 116) are operatively connected
to an appropriate substructure (62, 100) and the lightweight blocks
(12, 112) are operatively connected to the support beams (16, 116).
The blocks (12, 112) and support beams (16, 116) are configured so
that when they are connected to each other, a space is formed
between the wall structure (10, 110) and the substructure (62,
100). Thus, an assembled wall structure (10) may be setoff from a
substructure and the substructure (62, 100) may be used for other
purposes.
Inventors: |
Price, Raymond R;
(Rochester, MN) ; Price, Gerald P; (Rochester,
MN) |
Correspondence
Address: |
MOORE, HANSEN & SUMNER
2900 WELLS FARGO CENTER
90 SOUTH SEVENTH STREET
MINNEAPOLIS
MN
55402
US
|
Family ID: |
30115468 |
Appl. No.: |
10/363999 |
Filed: |
February 28, 2003 |
PCT Filed: |
April 12, 2001 |
PCT NO: |
PCT/US01/11957 |
Current U.S.
Class: |
52/605 ;
52/169.12 |
Current CPC
Class: |
E04B 2002/021 20130101;
E04B 2/06 20130101; E04B 2002/0245 20130101 |
Class at
Publication: |
52/605 ;
52/169.12 |
International
Class: |
E02D 001/00; B60R
027/00; E04C 002/04; E04B 005/04 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 20, 2000 |
WO |
PCT/US00/25791 |
Claims
What is claimed is:
1. A block for use in a wall structure comprising a plurality of
blocks stacked in columnar fashion with adjacent columns of blocks
operatively connected to each other by a plurality of elongated,
vertically oriented support beams, said block comprising: a front
face; a rear face spaced a predetermined distance from said front
face; a top surface; a bottom surface spaced a predetermined
distance from said top surface; and, opposing side surfaces, with
each opposing side surface including an outwardly extending,
vertically oriented finger; wherein, each finger is configured to
be frictionally engaged by an elongated, vertically oriented
support beam of a wall structure.
2. The block of claim 1, wherein each said finger is coextensive
with said opposing side surface.
3. The block of claim 1, wherein the front face and the rear face
have different surface finishes.
4. A block for use in a wall structure comprising a plurality of
blocks stacked in columnar fashion with adjacent columns of blocks
operatively connected to each other by a plurality elongated,
vertically oriented support beams, said block comprising: a front
face; a rear face spaced a predetermined distance from said front
face; a top surface; a bottom surface spaced a predetermined
distance from said top surface; and, opposing side surfaces, with
each opposing side surface including two substantially parallel,
outwardly extending, vertically oriented fingers; wherein, the
substantially parallel fingers of each opposing side surface are
configured to engage a portion of a vertically oriented support
beam of a wall structure therebetween.
5. The block of claim 4, wherein each said finger is coextensive
with said opposing side surface.
6. The block of claim 4, wherein the front face and the rear face
have different surface finishes.
7. A wall structure comprising at least two blocks stacked together
in a columnar fashion and at least two elongated, vertically
oriented support beams, with each block including a front face, a
rear face spaced a predetermined distance from said front face, a
top surface, a bottom surface spaced a predetermined distance from
said top surface and, opposing side surfaces, with each opposing
side surface including an outwardly extending, vertically oriented
finger; and with each elongated, vertically oriented support beam
including a web having at least one pair of laterally extending,
generally parallel ribs; wherein the support beams are vertically
positioned along the opposing side faces of the blocks and
operatively connect the blocks together in a columnar relation with
the ribs frictionally engaging the fingers of the blocks.
8. The wall structure of claim 7, wherein the support beam further
comprises an attachment member, wherein the attachment member is
configured to be operatively connected to a substructure.
9. The wall structure of claim 7, wherein the support beam further
comprises an attachment member, wherein the attachment member is
configured to be operatively connected to a bracket that is
operatively connected to a substructure.
10. The support beam of claim 7, wherein the longitudinal extent of
the support beam is less than the longitudinal extent of the
bracket to which it is operatively connected.
11. A support beam for use in constructing a wall structure having
at least two blocks stacked together in a columnar fashion, with
each block including a front face, a rear face spaced a
predetermined distance from said front face, a top surface, a
bottom surface spaced a predetermined distance from said top
surface and, opposing side surfaces, with each opposing side
surface including an outwardly extending, vertically oriented
finger; the support beam comprising: a web having at least one pair
of laterally extending, generally parallel ribs constructed and
arranged to operatively connect the blocks together in a columnar
relation as the ribs frictionally engage the fingers of the
blocks.
12. The support beam of claim 11, further comprising an attachment
member, wherein the attachment member is configured to be
operatively connected to a substructure.
13. The support beam of claim 11, further comprising an attachment
member, wherein the attachment member is configured to be
operatively connected to a bracket that is operatively connected to
a substructure.
14. The support beam of claim 11, wherein the generally parallel
ribs have different thicknesses.
15. The support beam of claim 11, wherein one of the generally
parallel ribs further comprises a forwardly facing viewable
surface.
16. A block for use in a wall structure comprising a plurality of
blocks stacked in columnar fashion with adjacent courses of blocks
in each column operatively connected to each other by an elongated,
vertically oriented support beam, said block comprising: a front
face; a rear face spaced a predetermined distance from said front
face, the rear face including an inwardly extending, vertically
oriented groove; a top surface; a bottom surface spaced a
predetermined distance from said top surface; and, opposing side
surfaces; wherein, the groove at the rear face is sized to receive
and engage a portion of an elongated, vertically oriented support
beam in a wall structure.
17. The block of claim 16, wherein the rear face further comprises
a second inwardly extending, vertically oriented groove sized to
receive and engage a portion of an elongated, vertically oriented
support beam in a wall structure.
18. The block of claim 16, wherein the opposing sides include a
projection and a recess, respectively, wherein the projection and
the recess are complimentarily shaped and configured to allow
adjacent blocks in a course of blocks to be brought into alignment
with each other by engaging the projection of one block within the
recess of an adjacent block.
19. A wall structure comprising at least two blocks stacked
together in a columnar fashion and engaged by at least one
elongated, vertically oriented support beam, with each block
including a front face, a rear face spaced a predetermined distance
from said front face, the rear face including an inwardly
extending, vertically oriented groove, a top surface, a bottom
surface spaced a predetermined distance from said top surface; and,
opposing side surfaces; with the support beam comprising of a web
having a rib, wherein the support beam operatively connects the
blocks together in a columnar relation with the rib received in and
engaging the grooves of the blocks.
20. The wall structure of claim 19, wherein the support beam
further comprises an attachment member, wherein the attachment
member is configured to be operatively connected to a
substructure.
21. The wall structure of claim 19, wherein the support beam
further comprises an attachment member, wherein the attachment
member is configured to be operatively connected to a bracket that
is operatively connected to a substructure.
22. A block for use in constructing a wall structure comprising a
plurality of blocks with adjacent courses of blocks operatively
connected to each other by a peg, said block comprising: a front
face, a rear face spaced a predetermined distance from said front
face, a top surface; a bottom surface spaced a predetermined
distance from said top surface, opposing side surfaces, and, a
plurality of vertically oriented apertures extending inwardly from
the top and bottom surfaces; wherein, the apertures are sized to
receive and engage a portion of a peg to enable adjacent courses of
blocks to be operatively connected to each other in a wall
structure.
23. The block of claim 22, wherein the opposing sides include a
projection and a recess, respectively, wherein the projection and
the recess are complimentarily shaped and configured to allow
adjacent blocks in a course of blocks to be brought into alignment
with each other.
24. A wall structure comprising at least two blocks stacked
together, a peg, an elongated, vertically oriented support beam,
and a web; with each block including a front face, a rear face
spaced a predetermined distance from said front face, a top
surface, a bottom surface spaced a predetermined distance from said
top surface; opposing side surfaces, and, a plurality of vertically
oriented apertures extending inwardly from the top and bottom
surfaces; with the peg configured to be received within the
aperture of adjacent courses of blocks and operatively connect the
blocks together; with the vertically oriented support beam
operatively connected to a substructure; and, with the web
operatively connecting the connected blocks to the support
beam.
25. The combination of a vertically oriented support beam and a
bracket for stabilizing a wall structure of the type comprising a
plurality of blocks stacked upon each other in a columnar fashion,
the support beam comprising a web with a laterally extending rib
and an attachment member; the bracket comprising a substructure
engaging portion connected to a support beam engaging portion;
wherein the plurality of blocks are operatively connected to each
other by the rib of the vertically oriented support beam; wherein
the vertically oriented support beam is operatively connected to
the support beam engagement portion of the bracket by the
attachment member of the support beam; and wherein; the support
beam is operatively connected to a substructure to thereby
stabilize said wall structure.
26 A device for use in supporting a wall structure of the type
having a plurality of blocks stacked in columnar fashion with
adjacent columns of blocks operatively connected to each other by a
plurality of elongated, vertically oriented support beams, with the
support beams including an attachment member; the device
comprising; an elongated, vertically oriented post having a
vertically oriented bracket, with the bracket configured to
operatively engage an attachment member of an elongated support
beam; wherein a wall structure may be operatively connected to the
device in a supporting relation.
27 A method of assembling a wall structure, the method comprising
the steps of: a. installing a first elongated support beam in a
generally vertical orientation; b. placing a first block adjacent
the beam so one side of the block engages a portion of the first
support beam; c. placing a second block on top of the first block
in a columnar fashion so that one side of the second block is
adjacent to and engages another portion of the first support beam;
and d. installing a second support beam adjacent unengaged sides of
the first and second blocks so that portions of the second support
beam engage both the first and second blocks and complete the wall
structure.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention is drawn to a wall structure that may
be adapted for use in many applications. Specifically, the present
invention is a wall structure that may be used in a variety of
interior and exterior applications, for example, as a skirting
wall, as wainscoting, as a small retaining wall, as a pool wall, as
a veneer or fascia, as cladding or siding, as a fence, and as a
load-bearing or non load-bearing wall.
[0002] Transportable structures such as mobile homes, trailer
homes, modular homes and recreational vehicles are usually not
built upon a conventional foundation. Rather, they are brought or
driven to a location where they remain for indeterminate periods of
time. Often, over an extended period at a particular site, such
structures may start to settle onto or in the ground due to factors
such as deflating tires or weight of the structure. Or, settling
may be the result whether related factors such as erosion and
freeze-thaw cycles. As a result, such structures may shift and/or
sink. In order to prevent shifting and sinking of these structures,
and moreover to ensure the structure is level regardless of the
ground's topography, they are usually placed on stilts or supports
that extend from the ground and elevate the structure thereabove.
While this solves the aforementioned problem of shifting and/or
sinking, it causes an unsightly visible gap in the area between the
ground and the bottom of the structure.
[0003] Various attempts to cover the unsightly visible gap have
included the use of plants, rocks, wood, plastic and masonry
blocks. These structure skirting efforts were either prohibitively
expensive, difficult to install, or unattractive and unable to
withstand sustained exposure to nature's elements. Solutions that
tend to be prohibitively expensive or difficult to install include
large, custom-made, cement slabs having a decorative face, and the
use of standard cinder blocks and mortar to build a wall around the
bottom of the structure. Attempts that fall into the latter
category include such easily breakable products as wooden or
plastic lattices and plastic or foam panels that imitate a stone or
brick wall. Consequently, there is a need for a sturdy,
inexpensive, easily assembled wall structure for skirting a
transportable structure such as a mobile home.
[0004] In other applications, where brick, stone, or concrete is
used as veneer or fascia, for fencing, and as load-bearing and non
load-bearing walls, these structures are typically
non-transportable and permanent in nature. That is, the component
parts are assembled as part of a larger structure that are not
intended to be easily dismantled. With veneer, for example, a
substantial portion of the rearwardly facing surface is typically
coated with adhesive or cementatious material to enable the veneer
to be securely and directly bonded to a structure. As another
example, walls may be constructed in a conventional manner with
blocks and mortar, or they may comprise heavy blocks that interlock
with each other without the use of mortar. As one may well imagine,
it is very difficult and time consuming to reconfigure, remove or
repair such structures. In addition, the erection of these
structures typically requires specialized knowledge and skills to
achieve. In light of these shortcomings, there is an additional
need for a wall structure that may be easily assembled,
disassembled and rebuilt or reconfigured by an unskilled user
without damage to the constituent parts of the wall structure and
which may be used as a veneer, fascia, cladding, fence, or as a
load-bearing or non load-bearing wall.
SUMMARY OF THE INVENTION
[0005] One embodiment of the present invention provides a composite
masonry block and wall system to be used to skirt elevated
structures. The block is shaped to be stacked in vertically
independent columns, held in place by specially shaped,
lightweight, support beams placed between adjacent columns, and
also by U-shaped lateral supports which open downwardly and are
attached to the bottom of the elevated structure.
[0006] Preferably, the blocks comprise a split front face, a rear
face, top and bottom surfaces, and side surfaces. The side surfaces
include grooves for receiving supporting portions of the support
beams. The top and bottom surfaces are preferably shaped so that
when an upper block is stacked on a lower block, the lower surface
of the upper block sits on the upper surface of the lower block and
the two blocks are relatively coplanar and vertical. This
configuration is most easily accomplished using blocks having flat
top surfaces and flat bottom surfaces that are relatively
perpendicular to the front and rear faces. It would also be
possible to accomplish this vertical block-to-block relationship
using top and bottom surfaces comprised of complementary angles
and/or curves.
[0007] The support beams are preferably a weather resistant metal
or plastic, nylon or other synthetic, durable, inexpensive
material, such as poly-vinyl chloride (PVC). The purpose of the
beams is to keep the independent vertical columns from buckling
when subjected to a force normal to the plane of the wall. The
rigidity of the blocks provides enough support to prevent failure
in other directions. This purpose may be accomplished using
relatively thin beams having lateral extensions for being received
by the grooves in the sides of the blocks.
[0008] Preferably, the beams serve to stabilize and maintain the
blocks in independent vertical columns and they provide little or
no support in the vertical direction. The columns are considered
independent because, unlike conventional brick or stonewalls, one
horizontal course of blocks is aligned with the adjacent upper and
lower courses so that the blocks in each course are in line with
the blocks above and below them, as opposed to being laterally
offset. This results in the formation of vertical columns of blocks
that can move up and down, due to forces exerted by the
ever-shifting earth, without upsetting, or otherwise exerting
forces on, adjacent columns of blocks.
[0009] The resulting wall of this system is surprisingly strong. It
may even be used to provide support to the elevated structure. Once
installed the elevated structure may be lowered onto the blocks.
Alternatively, the blocks may merely serve as a skirt, which
improves the aesthetics of the structure and keeps unwanted birds
and animals from nesting or otherwise residing under the structure.
In this embodiment, it is not necessary that the blocks make actual
contact with the structure.
[0010] The use of the lateral support beams also obviates the need
for mortar between the blocks. This mortarless system is
advantageous over traditional brick and mortar walls for obvious
reasons. First, fewer materials are required to build a wall. Thus
the cost of transporting the materials to a site is reduced.
Second, great physical strength and stamina are not required
because the materials used are lighter. Moreover, since less
stamina is required, a person is able to work for longer periods of
time without breaks. And, because of the relative lightness of the
materials used, on the job injuries due to overexertion and/or
fatigue are reduced. Third, no special skills are required to
construct a mortarless wall structure. Fourth, a mortarless wall
structure may be constructed by one person. Thus the need for an
additional person to mix and deliver mortar at a site is
eliminated--further reducing cost of construction. Fifth, since
there are no time constraints imposed by drying mortar, a person
can construct a wall at their own pace. Sixth, a mortarless wall
structure may be constructed under conditions, which, for a
conventional block and mortar wall, would be extremely difficult or
impossible. Also, the loose block system may be constructed on a
wide variety of surfaces, including soils such as sand, gravel, or
dirt, concrete, or construction elements such as wood or steel
beams, flooring, sills, thresholds, etc.--it is not necessary to
pour a foundation.
[0011] The lateral support beams also allow the use of relatively
thin blocks. These thin, wafer-like blocks are relatively
lightweight, resulting in ease of handling and shipping, and a
reduction in material costs. The blocks are preferably between 1
and 4 inches (2.5-10 cm.) thick, more preferably on the order of
21/2 inches (6.0 cm.) thick. As they are generally between 6 and 12
inches (15-30 cm.) in height and between 6 and 24 inches (15-60
cm.) in width, it would be difficult to use such a tall thin block
to create a brick wall using mortar. The tall, thin blocks would
have to be held in place somehow to allow the mortar to dry.
However, tall thin blocks provide certain advantages and the
present invention provides a way of incorporating the advantageous
of such a block. These advantages include an increased front face
surface area, resulting in a more attractive wall. The design also
provides increased lateral support, ideal for use with such a beam
system.
[0012] The loose block system also allows the wall to be
disassembled and reassembled. This not only gives flexibility
during initial construction, but also allows later renovations to
be made easily and inexpensively. For instance, may be desirable to
vent wall structures such as skirting walls to prevent the buildup
of moisture or condensation between the ground and the elevated
structure. These vents can be easily installed into an existing
wall, especially if they are of similar dimensions and
configurations as the blocks. The blocks of a given column are
simply removed and reinstalled, replacing one of the blocks with
the vent. Other auxiliary items, such as an access door or lights,
could be installed in a similar manner.
[0013] The wall design of the present invention also allows a wall
corner to be constructed without supporting beams or mortar. Two
walls are simply aligned to form a butt joint and fasteners such as
appropriate plastic pegs or screws and plastic inserts are used to
fasten one wall to the other. Alternatively, construction mastic,
or a similar type of adhesive, may be applied instead of or in
combination with the screws. Again, ease of installation is greatly
improved by the loose block, mortarless system of the present
invention.
[0014] Another embodiment of the present invention is well suited
for use as a veneer or as wainscoting. In this embodiment, the
support beam also includes one or more leg structures that extend
from the support beam toward a structure over which the wall
structure will be applied as a veneer. The leg structure comprises
a leg and a foot that are preferably arranged at right angles to
one another and to the support beam, but which may be constructed
at any appropriate angle.
[0015] A double-ended support beam is useful in adapting the wall
structure of the present invention to the creation of a
double-sided wall. In this embodiment of the present invention, two
block engaging structures comprising a web and at least one rib
extending therefrom are coupled together in a spaced apart
relationship by a spacer or web. The respective block engaging
structures engage the grooves between the side edges of adjacent
block columns of respective wall faces to couple the wall faces
together.
[0016] Another embodiment of the support beam of the present
invention is useful in constructing walls having a single face. In
this embodiment, the support beam comprises a block engaging
structure that extends from a solid or hollow elongate post. The
block engaging structure of this support beam preferably comprises
a web having extending therefrom a pair of ribs that are
constructed and arranged to engage the opposing grooves formed in
the side surfaces of adjacent block columns in the wall face. The
post portion of this support beam can be secured directly to a wall
support structure such as a foundation, footing, ledge, or bracket.
Where the post portion of the support beam is hollow, the support
beam can be slipped over a structural member that is secured
directly to a wall support structure such as a foundation, footing,
ledge, or bracket.
[0017] In another embodiment of the support beam, the web includes
an extension portion and an attachment member that may be
operatively connected to a substructure by fastening elements,
adhesive, clips, or two-part fasteners, for example. When the
attachment member is operatively connected to a substructure, the
extension portion positions the ribs of the support beam (and hence
the blocks of the support wall) away from the substructure in a
spaced relation. The setoff provided by this embodiment greatly
increases the number of uses of the wall structure because the
space between the wall structure and the substructure is now
available for other uses such as conduits, plenums, additional
insulation, etc. The blocks used in this embodiment are preferably
symmetrical and may be reversed, if desired.
[0018] Another embodiment of the wall structure uses elongated
blocks that have been provided with one or more transverse channels
that are configured to operatively engage a support beam which, in
turn, is operatively connected to a substructure. The elongated
blocks may also be provided with complimentarily shaped projections
and recesses at opposing sides that serve to align adjacent blocks
and strengthen the wall structure. As with the previous embodiment,
a wall structure using these blocks may be setoff from the
substructure to which it is operatively connected and the space
therebetween may be available for other uses.
[0019] Still another embodiment of the wall structure uses
elongated blocks that are operatively connected to each other by a
plurality of pegs that are operatively connected a substructure by
webs, and support beams. These elongated blocks are also provided
with complimentarily shaped projections and recesses at opposing
sides that serve to align adjacent blocks and strengthen the wall
structure. As with the previous embodiment, a wall structure using
these blocks may also be setoff from the substructure to which it
is operatively connected and the space therebetween may be
available for other uses.
[0020] A final embodiment of the wall structure includes a support
beam having forwardly facing, viewable surface. The viewable
surface may be provided with a surface which is similar to the
blocks it is retaining, or it may be provided with a contrasting
surface. Alternatively, the viewable surface of the support beam
may be provided with an additional cap or strip of material similar
to that of the blocks of the wall structure, and the cap or strip
may be otherwise textured or modified. The blocks used in
conjunction with this support beam include single opposing,
laterally extending, aligned fingers that are offset from the
center plane of the blocks in an coplanar relation and which enable
the blocks to be operatively connected to a support beam or beams
in several orientations. The blocks have front and rear faces which
may have similar or different surface textures and designs. As with
the earlier described embodiment the blocks may be reversed if
desired, so that either the front face or the rear face may be
viewed. With the support beam and block of this embodiment, a wide
variety of visually distinctive surfaces as well as a
conventionally configured surfaces are possible.
[0021] These and other objectives and advantages of the invention
will appear more fully from the following description, made in
conjunction with the accompanying drawings wherein like reference
characters refer to the same or similar parts throughout the
several views. And, although the disclosure hereof is detailed and
exact to enable those skilled in the art to practice the invention,
the physical embodiments herein disclosed merely exemplify the
invention, which may be embodied in other specific structure. While
the preferred embodiment has been described, the details may be
changed without departing from the invention, which is defined by
the claims.
DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of an elevated structure
skirted with an embodiment of the wall structure of the present
invention;
[0023] FIG. 2 is a perspective view of an embodiment of a block of
the present invention;
[0024] FIG. 3 is a perspective view of an embodiment of a support
beam of the present invention;
[0025] FIG. 4 is a side elevational view of a column of the present
invention taken generally along lines 4-4 of FIG. 1;
[0026] FIG. 5 is a plan view, taken generally along lines 5-5 of
FIG. 1, of two adjacent blocks of the present invention abutted and
held by a support beam;
[0027] FIG. 6 is a plan view of two blocks abutted with a support
beam installed using an alternative configuration;
[0028] FIG. 7 is a plan view of two blocks being pressed together
and resiliently deforming a support beam;
[0029] FIG. 8 is a plan view of two blocks abutted with an
alternative embodiment of a support beam;
[0030] FIG. 9 is a plan view of two blocks abutted with another
alternative embodiment of a support beam;
[0031] FIG. 10 is a plan view of an embodiment of a corner of the
wall structure of the present invention;
[0032] FIG. 11 is a plan view of a two abutting blocks with another
alternative embodiment of a support beam coupling the blocks to an
existing structure;
[0033] FIG. 12 is a plan view of a two abutting blocks with another
alternative embodiment of a support beam coupling the blocks to an
existing structure;
[0034] FIG. 13 is a plan view of a two abutting blocks with another
alternative embodiment of a support beam coupling the blocks to an
existing structure;
[0035] FIG. 14 is a plan view of a double-sided free standing wall
structure wherein the respective sides of the wall structure are
coupled together by a double ended support beam; and,
[0036] FIG. 15 is a plan view of a freestanding wall structure in
which the support beam is formed integral to a post.
[0037] FIG. 16 is a perspective view of another preferred
embodiment of support beams and blocks used to construct a wall
structure of the present invention;
[0038] FIG. 17A is partial, perspective view of a support beam of
the preferred embodiment of the wall structure of FIG. 16;
[0039] FIG. 17B is a partial, top plan view of the support beam of
FIG. 17A as it may be used to operatively connect blocks to a
substructure;
[0040] FIG. 18A is partial, perspective view of another embodiment
of a support beam and bracket that may be used in conjunction with
blocks of FIG. 16 to construct a wall structure;
[0041] FIG. 18B is a partial, top plan view of the support beam and
bracket of FIG. 18A as they may be used to operatively connect
blocks to a substructure;
[0042] FIG. 19A is a partial, perspective view of another
embodiment of a support beam and bracket that may be used in
conjunction with blocks of FIG. 16 to construct a wall
structure;
[0043] FIG. 19B is a partial, top plan view of the support beam and
bracket of FIG. 19A as they may be used to operatively connect
blocks to a substructure;
[0044] FIG. 20A is a partial, perspective view of another
embodiment of a support beam and bracket that may be used in
conjunction with blocks of FIG. 16 to construct a wall
structure;
[0045] FIG. 20B is a partial, top plan view of the support beam and
bracket of FIG. 20A as they may be used to operatively connect
blocks to a substructure
[0046] FIG. 21A is a partial, perspective view of an embodiment of
a post having an integrally formed support beam and an integrally
formed bracket, with the post used to construct a double-sided wall
structure;
[0047] FIG. 21B is a top plan view of the post of FIG. 21A with the
addition of partially depicted, differently sized wall blocks
operatively connected thereto;
[0048] FIG. 22A is a perspective view of another preferred
embodiment of support beams and blocks used to construct a wall
structure of the present invention;
[0049] FIG. 22B is a partial, perspective view of an embodiment of
a support beam that may be used to operatively connect a block of
the wall structure of FIG. 22A to a substructure;
[0050] FIG. 22C is a partial, perspective view of an alternative
embodiment of a support beam and a bracket that may be used to
operatively connect a block of the wall structure of FIG. 22A to a
substructure;
[0051] FIG. 23A is a perspective view of another preferred
embodiment of support beams and blocks used to construct a wall
structure of the present invention;
[0052] FIG. 23B, is a partial, side view of an embodiment of a web
and a support beam that may be used to operatively connect blocks
of the wall structure of FIG. 23A to a substructure;
[0053] FIG. 23C is a partial, exploded perspective view of an
embodiment of a web and a support beam that may be used to
operatively connect blocks of the wall structure of FIG. 23A to a
substructure;
[0054] FIG. 23D is a partial plan view illustrating apertures and
pegs of the wall structure of FIG. 23A;
[0055] FIG. 24A is a partial, perspective view of a preferred
embodiment of a support beam used to construct a wall structure
similar to the wall structure of FIG. 16;
[0056] FIG. 24B is a partial, top plan view of an alternative
embodiment of the support beam of FIG. 24A as it may be used to
operatively connect blocks to a substructure; and
[0057] FIG. 24C is a partial, top plan view of the support beam of
FIG. 24A as it may be used to operatively connect blocks to a
substructure.
DETAILED DESCRIPTION
[0058] Referring now to the drawings and first to FIGS. 1-4, there
is shown a wall structure 10 comprised of a plurality of blocks 12
forming columns 14 partially spaced apart and held in place by
vertically oriented, lateral support beams 16. Downward opening
brackets 18 attached to the bottom of the structure being skirted,
are placed over the top block 12 of selected columns 14 to help
prevent wall 10 from tipping rearwardly or forwardly. As used
herein, the term "forward" means away from the center of the
elevated structure and the term "rearward" means toward the center
of the elevated structure.
[0059] Attention is now directed to the individual components of
wall system 10. FIG. 2 depicts a preferred embodiment of block 12.
It can be seen that block 12 generally comprises a front face 20, a
rear face 22, a top surface 24, a bottom surface 26 and side
surfaces 28A and 28B. Block 12 is preferably made of a dry
composite masonry material, which hardens quickly when compressed
in a mold. It is envisioned that other materials could be used,
such as concrete, fiberglass, ceramics, hard plastics, or dense
foam. The present invention would also be achieved if blocks 12
were formed of wood, preferably treated wood. Though the general
shape of the blocks is more important to achieve the present
invention than the material used, it has been found that the
aforementioned preferred dry composite masonry material provides
the most desirable combination of strength, appearance, economy,
and ease of manufacturing.
[0060] Front face 20 is forwardly spaced from rear face 22 by a
predetermined distance herein defining the depth 30 of block 12. As
shown in FIG. 2, it is envisioned that front face 20 is formed
using a splitting process, thereby forming an attractive, roughened
face. This, however, is not necessary to carry out the spirit of
the invention. Front face 20 could alternatively be molded,
pressed, carved, etched, painted, or otherwise formed in any
manner. Preferably, depth 30 is relatively constant throughout the
extents of block 12, excepting the variations caused by the
splitting process and also excepting splitting recesses or other
interruptions in the split look of front face 20. Splitting
recesses 21 are preferably formed in front face 20 to provide an
area for splitting block 10 along a straight line.
[0061] Top surface 24 is separated from bottom surface 26 by a
distance defining the height 32 of block 12. When blocks 12 are
arranged vertically to form a column 14, bottom surface 26 of any
block 12 other than the bottom block of a column, rests on the top
surface 24 of the block below. It is therefore preferred that top
surface 24 and bottom surface 26 are so shaped to facilitate a
stacking relationship between two blocks 12 that results in an
upper block 12 resting vertically on a vertically oriented lower
block 12. This relationship is most easily achieved by making top
surface 24 and bottom surface 26 flat and relatively perpendicular
to rear face 22 and/or front face 26, as shown in the Figures.
Alternatively, it is envisioned that top and bottom surfaces 24 and
26 be comprised of complementary angles which are not perpendicular
to rear face 22 and/or front face 26, but result in the vertical
relationship between upper and lower blocks 12, described above. It
is also envisioned that this relationship be achieved through the
use of concave and convex surfaces or using tongue and groove
configurations.
[0062] Side surfaces 28A and 28B, as shown in FIG. 2, are
preferably somewhat perpendicular to rear face 22 and/or front face
20 and preferably comprise a groove 34 for receiving a portion of
beam 16, shown in FIG. 3. Alternatively, it is envisioned that one
side surface 28A or 28B have a groove and the other side surface
have a tongue configured to mate with the groove, thereby obviating
the need for beams 16. However, in order to maintain the vertically
independent characteristics of columns 14, the use of beams 16 is
preferred.
[0063] Beams 16, shown in FIG. 3, preferably comprise a spine or
web 36 and at least one rib 38. Preferably, there are two pairs of
ribs 38A and 38B. This configuration of two pairs of ribs 38A and
38B attached to each other by web 36 forms somewhat of an I-beam
configuration. It is preferred that one set of ribs 38A are
resiliently deformable and even more preferred that they comprise
flanges 40 to assist in guiding them into grooves 34. A biased,
resiliently deformed rib 38A exerts an even force on groove 34 as
it pushes thereagainst towards rib 38B and prevents unwanted
movement and misalignment between blocks 12 of a given column
14.
[0064] The distance between rib 38A and 38B is herein defined as
the span 42 of the rib. The span 42 should either be as great as
the distance between the groove 34 and the rear face 22, or, in the
case of the resiliently deformable rib 38, should be able to
achieve this distance through deformation when installed into the
groove 34 of a block 12.
[0065] Beams 16 may or may not be attached at their upper ends to
the structure being skirted, at or near its bottom. Attaching beams
16 thusly provides support and stability to the independent columns
14, preventing them from leaning or falling forwardly or
rearwardly. Beams 16 also act to align the blocks 12 of a given
column 14, ensuring that the blocks maintain a somewhat coplanar
relationship.
[0066] FIGS. 6-9 show a variety of envisioned beam constructions
and arrangements. FIG. 6 shows a preferred arrangement of the
preferred beam construction shown in FIGS. 3 and 5. It can be seen
that preferably, beam 16 is placed in the opposing grooves 34 of
adjacent blocks 12 so that resiliently deformable ribs 38A having
flanges 40 are rearward of ribs 38B. Doing so utilizes the forces
exerted by the bias of ribs 38A to urge the forward edges of
opposing sides of adjacent columns of blocks 28A and 28B together
to minimize gaps therebetween. Arrows 41 represent these forces.
FIG. 7 shows how flanges 40 act to guide block 12 as it moves
toward and engages beam 16.
[0067] FIG. 8 shows an alternative embodiment of beam 16 having two
ribs 38B but only one resiliently deformable rib 38A. FIG. 9 shows
yet another embodiment of a beam 16 comprising one pair of opposed
ribs 38B such that the support beam 16 is essentially an elongate
spline.
[0068] It is envisioned that brackets 18 be used in conjunction
with beams 16 to provide stability to wall 10. Referring now to
FIG. 4, it can be seen that brackets 18 comprise a front wall 44
having a top edge 45 and a bottom edge 47, a rear wall 46
rearwardly spaced apart from front wall 44, and a top wall 48
joining top edge 45 of front wall 44 and rear wall 46. Front wall
44 and rear wall 46 define a downward opening 50 into which the top
surface 24 of the top block 12 of a column 14 may be inserted. In
operation, bracket 18 is attached to the underside of a structure
to be skirted and positioned so that the top block 12 of a column
14 is inserted into opening 50 and so that the bracket is located
near the middle of the block 12. It may be desired to make rear
wall 46 of a greater vertical dimension that front wall 44 to
provide additional support. It may also be desired to provide a
bracket 18 with a rear wall 46, which extends in a lateral
direction further than front wall 44. Furthermore, it is envisioned
that brackets 18 could be a variety of lengths. For instance,
brackets 18 could be as short as one inch or as long as the entire
wall.
[0069] Brackets 18 prevent rearward or forward movement of column
14 and also work in conjunction with beams 16 to prevent those
columns 14 without brackets 18 from tipping over rearwardly or
forwardly. As it is envisioned that beams 16 may or may not be
attached to the structure, brackets 18 may be solely responsible
for preventing wall 10 from tipping over. Brackets 18 can be of any
suitable material, preferably synthetic, more preferably poly-vinyl
chloride (PVC) or other durable plastic. It may be advantageous to
make brackets 18 and beams 16 out of similar material.
[0070] FIG. 10 shows a preferred corner configuration using the
blocks 12 of the present invention. The design of block 12 lends
itself to the formation of corners without the need for mortar,
corner braces, or other supports. Two blocks 12A and 12B are simply
aligned to form a corner butt joint 51. Preferably block 12B is
broken along its splitting recess 21 to form a new split face 52
which roughly matches split front face 20 of block 12A. Holes 54
are drilled through blocks 12A and 12B so that fastener 56 may be
inserted. Fastener 56 may be any suitable fastener, preferably a
screw or peg. Preferably such as appropriate plastic pegs or screws
and plastic inserts are used to fasten one wall to the other.
Alternatively, glue, preferably construction mastic 58, may be
applied instead of or, more preferably, in combination with
fasteners 56.
[0071] FIGS. 11-15 illustrate additional embodiments of the present
invention. FIG. 11 illustrates a support beam 16 having a pair of
leg structures 59 that are constructed and arranged to secure a
wall comprising columns 14 of blocks 12 to an existing support
structure 62. The support structure may be a building or any other
type of structure that may support a wall structure 10 according to
the present invention. Leg portions 60 of the leg structures 59
extend rearwardly from the support beam 16 and are preferably
secured to one of the ribs 38A or 38B thereof. The leg structures
59 may also be formed as part of the web 36 of the support beam 16.
Legs 60 have a foot 64, which extends laterally from the legs 60 to
provide a point of connection for the support beam 16 to the
existing structure 62. Nails, screws, or other appropriate
fasteners 66 are driven through the feet 64 of the support beam 16
and into the sheathing 68 of the wall of the existing structure 62.
The sheathing 68 of the typical wall is typically supported by a
plurality of horizontal girts 70. Once the support beam 16 has been
secured to the existing structure 62, blocks 12 are stacked between
respective support beams 16 as illustrated in FIG. 11 such that
ribs 38A of the support beam 16 are inserted into the grooves 34 in
the sides of the blocks 12. Note that the number, construction, and
arrangement of ribs 38A and 38B may vary as described above in
conjunction with FIGS. 5-9.
[0072] In order to prevent the inflow of water into the wall
structure 10, it may be desirable to apply a bead of a waterproof
material 90 such as mastic or caulk along the top surface 24 of the
blocks 12. The bead of waterproof material 90 forms a seal between
the upper surface 24 of the lower block 12 upon which the bead has
been placed and the lower surface 26 of the block 12 immediately
above the lower block.
[0073] Legs 60 of support beam 16 are preferably extend rearwardly
from ribs 38B in a perpendicular relationship thereto. Similarly,
it is preferred that the feet 64 of the support beam 16 extend
laterally perpendicular to the legs 60. The perpendicular
relationship of the feet and legs to the remainder of the support
beam 16 is the preferred embodiment thereof, it must be kept in
mind that the purpose of the legs 60 and feet 64 is to provide and
offset for the block wall 10 from the wall of the existing
structure 62. This offset allows a concrete block wall 10 to be
secured over uneven surfaces such as the steel siding 72
illustrated in FIG. 11. As can be seen, legs 60 of support beam 16
are sufficiently long such that the support beam clears ridge 73 of
the steel siding 72. As can be appreciated, steel siding 72
typically presents a vertically flat surface. Where a wall
structure 10 is to be applied to a wall of an existing structure 62
that is not vertically smooth, furring strips or blocking may be
fastened to the wall of the existing structure 62 as needed. As
support beam 16 provide no vertical support for the blocks 12, the
blocks must be provided with some sort of foundation. Examples of
suitable foundation include a concrete pad or footing that is sunk
into the ground, and a cantilever ledge or bracket which is
securely affixed to the wall of the existing structure.
[0074] FIG. 12 illustrates a support beam 16 having two pairs of
ribs 38A and 38B separated by a web 36 and only a single leg
structure 59 comprising a leg 60 and foot 64. The embodiment of
FIG. 12 is particularly useful when an obstruction such as ridge 73
of steel siding 72 would prevent one of the leg structures 59
illustrated in FIG. 11 from securely contacting the wall of the
structure 62. Fasteners 66 are sufficient to provide the requisite
lateral support for the wall structure 10. The support beam 16
having only a single leg structure 59 may be rotated end-for-end
depending on the offset location of an obstruction such as ridge
73.
[0075] Preferably the support beam 16 of the present invention will
be extruded or molded from a material such as a plastic, a fiber
reinforced resin, or a metal such as aluminum. In addition to
forming embodiments of support beams 16 having the respective
profiles of the support beams illustrated in FIG. 12, it is
possible that one leg structure 59 could be removed from a support
beam 16 such as the support beam 16 of FIG. 11 having two leg
structures 59, thereby resulting in the support beam embodiment
illustrated in FIG. 12. However, where a single leg structure 59
would be sufficient to provide the needed lateral support for a
wall structure 10, it would be more economical to manufacture
support 16 having only a single leg structure 59.
[0076] FIG. 13 illustrates a support beam 16 that is constructed
and arranged to provide lateral support to a wall structure 10 as
described in conjunction with FIGS. 11 and 12. The main difference
here being that the support beam 16 of FIG. 13 has a pair of ribs
38A and only a single rib 38B extending from the web 36. Leg
structure 59 extends rearwardly from the rib 38B preferably in a
perpendicular relation thereto. While it is preferred that the leg
60 and foot 64 be arranged at right angles to each other and to the
ribs 38B of the support beam 16, these structures may be arranged
at any angle to one another provided, of course, that there is a
sufficient offset from the wall of the existing structure 62 to
allow installation of the blocks 12 of the wall structure 10 and
that the feet 64 of leg structure 59 may be securely fastened to a
supporting structure 62.
[0077] FIG. 14 illustrates a double-ended support beam 80, which is
useful for constructing a wall structure 10 having a front face 74
and a rear face 76. The space 78 between the front and rear faces
74, 76 of the wall structure 10 of FIG. 14 may remain hollow or may
be filled. As can be seen from FIG. 14 the double ended support
beam 80 comprises two support beams 16 having a cross-sectional
profiles similar to the support beam 16 illustrated in FIG. 5
arranged back-to-back and space apart and connected by a spacer web
82. Spacer web 82 is connected to the base pair of ribs 38B of each
of the support beam portions in a perpendicular fashion. In this
manner, support beam 80 couples the front and rear sides of the
wall structure 10 to provide mutual lateral support for the sides.
Further support can be had by backfilling the space 78 between the
front and back sides of the wall structure 10 with gravel, earth,
or an insulating material. Preferably, a cap such as bracket 18
(See, FIG. 4) will be placed over the top of the wall structure 10
of FIG. 14 to prevent the ingress of water and nuisance
animals.
[0078] FIG. 15 illustrates a single sided wall structure 10
comprising columns 14 of blocks 12 supported by a post-like support
beam 84. Support beam 84 comprises a post 85 having extending
therefrom a web 36. A pair of ribs 38A extend laterally from the
web 36 in the same manner as the ribs of support beams 16 described
in conjunction with FIG. 3. As installed, post 85 is preferably
rigidly seated in a footing or foundation set into the ground below
the wall structure 10. As can be appreciated, blocks 12 are stacked
between respective post support beams 84 as described above. The
posts 85 of the post-support beam 84 preferably have a hollow cross
section. However, post 85 may also be a solid in cross section or
may have a reinforcing structure such as a pipe or a rod received
therein. An alternate embodiment for the post to support beam 84
involves securely seating a plurality of rods or members in
footings or a foundation beneath the wall structure 10 and sliding
the post beam 84 of the type illustrated in FIG. 15 thereover.
Blocks 12 would then be disposed between respective pairs of post
support beams 84 as described above.
[0079] With reference to FIG. 16, a partially assembled wall
structure 110 comprising a plurality of blocks 112 retained in
place by a plurality of vertically oriented, elongated support
beams 116 that are operatively connected to a substructure 100
(shown in dashed lines) is depicted. As can be seen, the support
beams 116 allow blocks 112 of adjacent horizontal courses to be
substantially superposed one above the other and not laterally
offset from each other in a bond pattern as one may expect of such
a wall structure. Thus, the wall structure 110 is comprised of a
plurality of adjacent columns 114A-D that may be operatively
connected to each other in a serial fashion. Each block 112 of the
wall structure 110 includes a front face 120, a rear face 122, a
top surface 124, a bottom surface 126 and opposing sides 127A,B.
Each opposing side 127A,B includes opposing grooves 134, 136
respectively, defined by pluralities of outwardly extending fingers
128A,C and 128B,D, with outwardly facing surfaces 130A,C and
130B,D.
[0080] Preferably, the blocks 112 are symmetrically formed, so that
either the front or rear face 120,122, respectively, may face
forwardly. This feature allows a block which has been damaged or
had its surface otherwise altered to be easily removed and
reinstalled by merely turning the block around (or over) so that
other good or undamaged side now being the viewable surface of the
block. In other words, the blocks are reversible. The front and
rear faces need not have the same surface treatment. That is, a
block may have a smooth front face and a roughened rear face. Or, a
block may have roughened front face and a decorated or non-planar
rear face. For example, in FIG. 16, the lower most blocks of column
114C and column 114D, respectively, have forwardly facing rear
faces 122 while the remaining blocks in the partially assembled
wall structure 110 have forwardly facing front faces. As depicted,
the viewable front faces 120 of the blocks 112 of the wall
structure 110 are smooth and the viewable rear faces 122 of the
blocks of the wall structure 110 are roughened or otherwise
decorated.
[0081] With reference to FIGS. 17A and 17B, the support beam 116 is
similar to the support beam of prior embodiments (See, for example,
FIG. 3) in that it includes a web 140 from which a plurality of
ribs 142A', 142A", 142B' and 142B" extend. In a departure from
previous embodiments, the support beam 116 of this embodiment
includes an extension 144 that terminates with an attachment member
146. Preferably, the extension 144 is aligned with, and extends
from the web 140 so as to position the attachment member 146 a
predetermined distance from the plurality of ribs. This serves
several purposes. As explained above, not only does this creates
spaces between a wall structure and a substructure that may be used
as plenums, conduits, or for retaining insulative, fire-retardant
or other building materials, but it also facilitates attachment of
the support beam 116 to a substructure 100 (shown in dashed lines).
Preferably, the attachment member 146 comprises feet 148A and 148B
that extend laterally in opposite directions from the extension 144
to provide a point or points of connection which may be used with
adhesive 132 or fastening elements such as nails or screws 133 in
attaching a support beam to a substructure.
[0082] Referring now to FIGS. 18A and 18B, the support beam 116,
again, has an extension 144 which terminates in an attachment
member 146 with feet 148A, 148B. However, in this embodiment the
extension 144 and the feet 148A, 148B are foreshortened. Note that
the support beam 116 is not directly connected to a substructure
but is operatively connected to a bracket 170 that is, in turn,
operatively connected to a substructure 100 (shown in dashed
lines). The bracket 170 includes a substructure engaging portion
172, a span 174 and an attachment member 176 with a support beam
engaging portion 177. The support beam engagement portion 177 is
sized to be snuggly received and frictionally retained within a
channel (150A or 150B) formed by a rib and a foot (142B', 148A;
142B", 148B, respectively) of the beam 116. Note that the support
beam 116 need not extend along the length of the bracket 170, and
more particularly the support beam need not be coextensive with the
side of a block to which it is operatively connected. The reason
for this is that a block need not be retained along its entire
length of its grooves to be adequately retained as part of a wall
structure. Instead, it is only necessary for a block to retained at
several points. Thus, the support beams 116 may take the form of
clips that attach to the bracket 170, and a block may be retained
at a plurality of predetermined locations such as its upper and
lower ends. It will be appreciated that such support beam clips may
be used to operatively connect a pair of blocks to a support
bracket by positioning the clips so that they span the interface
between two adjacent blocks. It will also be appreciated that the
support beam clip may be longer than a side of a block to which it
is operatively connected so that it may operatively connect more
than two blocks to a bracket.
[0083] The span 174 of the bracket 170 serves to position the
support beam 116 a predetermined distance from a substructure while
the substructure engaging portion 172 serves to attach the bracket
170 onto a substructure. As with the aforementioned embodiment the
bracket 170 may be operatively connected to a substructure using a
variety of fastening elements. It will be appreciated that the
support beam 116 of this embodiment may be used with an additional
bracket 170, if desired, to form a more robust connection between
the wall structure and a substructure.
[0084] Referring now to FIGS. 19A and 19B, the support beam 116
does not have an extension (depicted as 144 in FIGS. 17 and 18).
Rather, the beam 116 terminates at an attachment member 146 that
includes two spaced apart resilient walls 152, 154 having
confronting arms 156, 158 which define a slot 160 and channel 162
which are sized to admit and retain a second attachment member.
[0085] With this embodiment, the support beam 116 is not directly
connected to a substructure but is operatively connected to a
bracket 180 that is, in turn, operatively connected to a
substructure 100 (shown in dashed lines). This bracket 180 includes
substructure engaging portions 182, 184, a span 186 and an
attachment member 188. Preferably, the attachment member 188 is a
dart-shaped head 190 having shoulders 192, 194 which are configured
to engage arms 156, 158 in a constrained relation. That is, the
attachment member 146 of the support beam is sized to slidingly
receive the attachment member 188 within a slot 160 and channel 162
formed by the resilient walls 152, 154 and their confronting arms
156, 158. Thus, support beam 116 may be connected to bracket 180 in
a constrained manner. It will be appreciated that support beam 116
may be operatively connected to a bracket 180 in several ways. For
example, by positioning the channel 162 and the slot 160 attachment
member 146 over the dart-shaped head 190 and the span 186 of the
attachment member 188 of bracket 180 and then sliding the support
beam 116 down along the bracket 180 and interconnecting with an
already positioned block, or sliding down along the bracket and
later interconnecting with a block which is slid into position in a
similar manner. Alternatively, a support beam 116 may be
operatively connected to a bracket 180 by aligning the slot 160 of
the attachment member 146 opposite the apex of the dart-shaped head
190 and then pushing the support beam 116 towards the dart-shaped
head 190 until the arms 156, 158 of the attachment member 146
engage the shoulders 192, 194 of the dart-shaped head 190.
[0086] Support beam 116, like the support beam of FIG. 18, need not
extend along the length of the bracket 170, and more particularly
the support beam need not be co-extensive with the side of a block
to which it is operatively connected. The reasons for this have
been discussed in conjunction with the description of FIGS. 18A and
18B, and for purposes of brevity will not be repeated. The span 186
of bracket 180 serves to position the support beam 116 a
predetermined distance from a substructure and the substructure
engaging portion 182, 184 serves to attach the bracket 180 onto a
substructure. As with the aforementioned embodiment the bracket 170
of FIG. 18, bracket 180 may be operatively connected to a
substructure using a variety of fastening elements 196.
[0087] Referring now to FIGS. 20A and 20B, the operative connection
is reversed from FIGS. 19A and 19B. That is, support beam 116
includes an extension 146 that terminates in an attachment member
146 having a dart-shaped head 212 with shoulders 214, 216. The
bracket 200 now includes two spaced apart resilient walls 206, 207
having confronting arms 208, 209 which define a slot 210 and
channel 211 which are sized to admit and retain attachment member
212 in a constrained relation, as discussed above. As with the
aforementioned embodiments, the support beam 116 need not extend
along the length of the bracket 200. And, the bracket 180 may be
operatively connected to a substructure using a variety of
fastening elements.
[0088] Referring now to FIGS. 21A and 21B, another preferred
embodiment depicts a post 220 which has been provided with a
plurality of connectors to enable the post to support a plurality
of wall structures. In this embodiment, the post 220 includes
opposing sides 222, 224 from which extend a web 226 and a bracket
230, respectively. A pair of ribs 228A', 228A" extend laterally in
opposite directions from the web 226 in the same manner as the ribs
of support beams 116 described in conjunction with FIG. 3, while
the bracket 230 includes the slot 232 and channel structure 234
similar to the slot and channel structures described and shown in
FIGS. 19A,B and 20A,B. Thus, with this embodiment, blocks may be
directly connected to the post 220 at side 222 or connected
indirectly at side 224 via an appropriately configured support
beam.
[0089] Other combinations of operative connections may also be
used. For example, the post 220 may be provided with two direct
connectors (webs with laterally extending ribs) or the post 220 may
be provided with two indirect connectors (attachment members, such
as channels). As will be appreciated, the post 220 may be
operatively connected to a substructure such as a footing or
foundation, or be set into the ground using known techniques and
technologies. While the post 220 is depicted as having a hollow
cross section, it is understood that the post 220 may also be a
solid in cross section or may have a reinforcing structure such as
a pipe or a rod received therein.
[0090] Referring now to FIG. 22A, a partially assembled wall
structure comprising a plurality of blocks 238 retained in place by
a plurality of vertically oriented, elongated support beams 260
that are operatively connected to a substructure 100 (shown in
dashed lines) is depicted. As can be seen, the support beams 260
allow blocks 238 of adjacent horizontal courses to be substantially
superposed one above the other and not laterally offset from each
other in a bond pattern as one may expect of such a wall structure.
Thus, the wall structure is comprised of a plurality of adjacent
columns that are operatively connected to each other in a serial
fashion as in FIG. 16A. Each block 138 of the wall structure
includes a front face 240, a rear face 242, a top surface 244, a
bottom surface 246 and opposing sides 248A,B. In a departure from
previous embodiments, each opposing side 248A,B includes a
projection 250 and a recess 252, respectively. As will be
appreciated the projection and the recess of each block may be
complimentarily shaped to facilitate alignment of adjacent blocks
in a course of blocks, and to add strength to a wall structure.
Note that the operative connection between the blocks and a support
beam is made at the rear of the block 238 through one or more
transversely oriented grooves 254. The grooves 254 are configured
to engage an attachment member of a support beam or bracket that is
operatively connected thereto. Preferably, each groove and
attachment member are complimentarily shaped in a dove-tail
fashion, however, other complimentary shapes may be used.
[0091] Referring now to FIG. 22B, a block 238 may be operatively
connected to a support beam 260 that is in turn operatively
connected to a substructure 100 (shown in dashed lines). Here, the
support beam 260 includes substructure engaging portion 261, an
extension 262 and an attachment member 264 that is configured as a
dove-tailed rib 266. The rib 266 is slidingly received within a
groove 254 so that when operatively connected to a support beam, a
block may be moved along the longitudinal axis of the support beam
260 in a constrained manner.
[0092] Referring now to FIG. 22C, a block 238 may be operatively
connected to a support beam 260 which is then operatively connected
to a bracket 270, which, in turn, is operatively connected to a
substructure 100 (shown in dashed lines). Here, the extension 262
of the support beam 260 is somewhat foreshortened and terminates in
a dart-shaped head 268 that extends away from the beam and is
configured to operatively connect to a bracket 270. The bracket 270
includes two spaced apart resilient walls 273, 274 having
confronting arms 275, 276 which define a slot 277 and channel 278
which are sized to admit and retain the dart-shaped head 268 in a
constrained relation--similar to that depicted in FIG. 20B.
[0093] Referring now, to FIG. 23A, a partially assembled wall
structure comprising a plurality of blocks 279 retained in place by
a plurality of vertically oriented, elongated support beams 260
that are operatively connected to a substructure 100 (shown in
dashed lines) is depicted. As can be seen, the blocks of one course
may be laterally offset from the blocks of an adjacent course in a
running bond. Each block 279 of the wall structure includes a front
face 280, a rear face 282, a top surface 284, a bottom surface 286
and opposing sides 288A,B that include a projection 290 and a
recess 292, respectively. As will be appreciated the projection and
the recess of each block may be complimentarily shaped to
facilitate alignment of adjacent blocks in a course of blocks, and
to add strength to a wall structure.
[0094] Unlike the previous embodiment, the operative connection
between the blocks 279 and a support beam 260 is indirect. That is,
the extension 262 of the support beam 260 terminates in a
dart-shaped head 268 that extends away from the beam and is
configured to operatively connect to a web 298, which, in turn is
operatively connected to blocks 279 of a wall structure 304. As
depicted in FIG. 23B, each block 279 includes one or more
transversely oriented apertures 294 that are configured to receive
a segment of a peg 296 that operatively connects adjacent courses
of blocks together. Each peg 296 is also operatively connects the
blocks 279 to a support beam 260 by a web 298. As best seen in FIG.
23C, each web 298 is provided with an aperture 300 through which
the peg 296 inserted, and an attachment member 302 that includes
two spaced apart resilient walls having confronting arms that
define a slot and channel that are sized to admit and retain the
dart-shaped head 268 of the support beam 260 in a constrained
relation--similar to that depicted in FIGS. 20B and 22C. It will be
appreciated that a web 298 may operatively connected to a support
beam 260 in several ways. For example, by positioning the
attachment member 302 over the dart-shaped head 268 of the support
beam 260 and then sliding the web 298 down along the support beam
until the web 298 encounters a block 279, which may or may not have
a peg already installed. Alternatively, a web 298 may be
operatively connected to a support beam 260 by aligning the slot of
the attachment member 302 opposite the apex of the dart-shaped head
268 and then pushing the web 298 towards the dart-shaped head 268
until the arms of the attachment member 302 engage the shoulders of
the dart-shaped head 268. Note that although the support wall 304
depicted in FIG. 23A and FIG. 23D is constructed in a running bond
pattern, other configurations are possible.
[0095] With reference to FIGS. 24A, 24B and 24C, the support beam
116 is similar to the support beam of prior embodiments (See, for
example, FIG. 7) in that it includes a web 140 from which a
plurality of ribs 142A', 142A", 142B' and 142B" extend. In a
departure from this previous embodiment, the support beam 116
includes an extension 144 that terminates with an attachment member
146. Preferably, the extension 144 is aligned with, and extends
from the web 140 so as to position the attachment member 146 a
predetermined distance from the plurality of ribs. In FIG. 24A, the
attachment member 146 is depicted as feet 148A and 148B, however it
is understood that the attachment member may take other forms such
as those depicted in FIGS. 18-20. Turning back to FIG. 24A, note
that the ribs 142A', 142A", 142B' and 142B" are reversed relative
to each other so that the pair of opposing ribs 142B' and 142B" are
now forward relative to the opposing pair of ribs 142A and 142A"
(similar to the rib arrangement as depicted in FIG. 7). Note also,
that the pair of forwardly facing opposing ribs 142B' and 142B" are
somewhat thicker than the pair of opposing ribs 142A' and 142A".
This feature allows the support beam 116 to have a viewable surface
143 which may form part of an observed wall structure. As depicted
in FIGS. 24B and 24C, ribs 142B', 142B" may be coplanar or
collateral relative to the viewable faces of blocks in a wall
structure.
[0096] Referring now to FIGS. 24B and 24C, the blocks 312 that are
used with the aforementioned beam 116 are similar to the blocks 112
depicted in the wall construction 110 of FIG. 16. That is, each
block 312 has a front face 320, a rear face 322, a top surface 324,
a bottom surface 326 and opposing sides 327. For purpose of
simplification, not all these surfaces are identified. One need
only refer to FIG. 16 to identify numerically similar numbers.
[0097] Each block 312 differs from the block 112 depicted in FIG.
16 in several respects. First, block 312 has only one pair of
opposing fingers 328A, 328B instead of the pair of opposing fingers
depicted in FIG. 16. Thus, each block 312 does not have a groove
that obscures a support beam rib. Instead of a groove, each block
312 has opposing ledges 334, 336 defined by pairs of side surfaces
330A, 330C, 330B, 330D and fingers 328A, 328B, respectively.
Preferably, the thickness of the ledges 334, 336 will be
substantially the same as the thickness of opposing ribs 142B',
142B", to enable the viewable surface of a wall structure to be
substantially contiguous. However, it is understood that the
thicknesses of the ledges and/or opposing ribs 142B', 142B" need
not be substantially the same. For example, the thickness of the
ribs 142B', 142B" may be greater than the thickness of the ledges
334, 336 of the blocks so that the viewable surface 143 of a
support beam projects outwardly with respect to the viewable
surface of the blocks of the wall structure, or the thickness of
the ribs 142B' 142B" may be less than the thickness of the ledges
334, 336 of the blocks so that the viewable surface 143 of the
support beam is recessed with respect to the viewable surface of
the blocks of the wall structure.
[0098] Another difference between block 312 and block 112 is that
the opposing laterally extending, aligned fingers 328A, 328B are
offset from the center plane of the block 312. As can be seen in
FIGS. 24B and 24C, this allows blocks to be operatively connected
to a support beam in several configurations. In FIG. 24B, for
example, blocks 312 are operatively connected to a support beam 116
so that front face 320 (left side) and rear face 322 (right side)
are substantially flush with the viewable surface 143 of the
support beam 116. As with the aforementioned blocks of FIG. 16, the
front and rear faces may have the same surface or may have
different surfaces. Here, the front face 320 on the left side of
FIG. 24B is depicted as being smooth, while the rear face 322 on
the left side of FIG. 24B is depicted as being roughened. The
viewable surfaces on the right side of FIG. 24B are reversed. In
FIG. 24C, the blocks 312 have been rotated so that when they are
operatively connected to the support beam 116 they are set back
from the viewable surface 143. It will be appreciated that the
blocks 312 need not be all coplanar or set back with respect to the
viewable surface 143 of the support beam 116. Combinations of set
backs and coplanar blocks are possible to create a myriad of wall
surfaces. It is contemplated that such combinations may be arranged
into identifiable forms or patterns and may also be arranged to
display alphanumeric characters and the like. Note that the
viewable surface 143 may be provided with a textured or otherwise
decorated surface which matches the surfaces of adjacent blocks.
Alternatively, as depicted in FIG. 24B, the viewable surface 143 of
the support beam may be provided with a cap or strip 145 of
material with a viewable surface 147 which may be textured or
otherwise decorated as desired and which may be affixed or attached
to the viewable surface 143 in a conventional manner.
[0099] It will be appreciated that the opposing, laterally
extending, aligned fingers of the aforementioned blocks (312) may
be aligned with the center plane of a block if desired. And, it
will also be appreciated that wall structures other than linear
structures are possible. For example, the support beams and blocks
may be used to construct circular, or sinuous structures by
providing curved blocks or blocks with one curved viewable surface
(when viewed cross-sectionally from a point above the top surface
of the block) that are operatively connected to support beams that
are similarly arranged. Or, a wall structure may be constructed in
a zigzag or erose form with the support beams collaterally arranged
relative to each other in a zigzag manner. To reduce vertical gaps
between forwardly facing viewable surfaces of adjacent blocks in
such a wall structure, it would be a matter of providing support
beams with ribs that are angled with respect to the web, mitering
or beveling the opposing sides of the blocks, or using a
combination of both angling and mitering the ribs and sides,
respectively. A similarly configured wall may also be constructed
using support beams arranged in a coplanar fashion relative to each
other and blocks having a predetermined, angular viewable surface
(when viewed cross-sectionally from a point above the top surface
of the blocks). For example, a V, L, or a W. Such blocks may have
parallel front and rear faces, if desired. With such a
construction, neither the support beams nor the opposing fingers
need to be modified. In a related construction, it is envisioned
that blocks be constructed having angles of ninety degrees so that
they may be used as inner or outer corners. With such blocks, the
opposing sides and their fingers would be perpendicular to each
other.
[0100] To construct a freestanding, low wall structure of the
present invention, a person would prepare or otherwise select an
appropriate location in which to construct a wall. The construction
would begin by placing a first block having opposing side grooves
in a desired position and orientation. Then, a second, similar
block would be placed directly on top of the first block so that
the opposing side grooves of the first and second blocks are in
vertical alignment with each other and the first and second blocks
form a column. Next, the first and second blocks would be
operatively connected to each other along their respective sides by
inserting at least one rib of first and second support beams into
the aligned grooves of the respective sides of the first and second
blocks and seating them securely. A second column comprising
similarly configured third and a fourth blocks may now be
constructed. The operation is much the same, except now the third
block is positioned so that one of its sides is adjacent to one of
the sides of the first block and its groove engages at least one
other rib of one of the already positioned support beams. The
fourth block is then positioned on top of the third block in a
similar manner. That is, the fourth block is positioned so that one
of its sides is adjacent to one of the sides of the second block
and its groove engages at least one other rib of one of the already
positioned support beam. After the second column is erected, the
third and fourth blocks would be operatively connected to each
other along their respective free side by inserting at least one
rib of a third support beam into their aligned vertical groove of
the respective sides of the first and second blocks and seating
them securely. And so on.
[0101] Another preferred method of constructing a wall structure
according to the present invention would be as follows. A person
would prepare or otherwise select an appropriate substructure on
which to construct a wall structure. The construction would begin
by operatively connecting a first elongated support beam to the
substructure in a vertical orientation. Then using the first
support beam as a reference, a series of support beams would be
operatively connected to the substructure, with all of the support
beams in vertical and collateral alignment, and with the distance
between adjacent support beams sufficient to enable the ribs of
adjacent beams to engage opposing side grooves of a block. Once the
dimensions of the wall structure have been established, the blocks
with opposing side grooves may be laid by sliding the blocks in a
vertical motion along the length of and between adjacent support
beams. This may be done course by course, column by column, or in a
mixture of both columns and courses, as desired.
[0102] In a variation of the aforementioned methods, the
construction would begin by operatively connecting a first
elongated support beam to the substructure in a vertical
orientation. Then a first block having opposing side grooves would
be placed in a desired position and orientation against the first
elongate support beam so that at least one of the ribs of the first
beam is seated within one of the side grooves of the block. Then, a
second, similar block would be placed directly on top of the first
block so that the at least one rib of the first beam is also seated
within one of the side grooves of the second block so that the
opposing side grooves of the first and second blocks are in
vertical alignment with each other and the first and second blocks
form a column. Next, the first and second blocks are operatively
connected to each other along their other respective sides by
aligning the grooves of the respective sides of the first and
second blocks, and inserting at least one rib of a second support
beam into the aligned grooves and seating it securely therein.
After the second support beam is seated, it is attached to the
substructure. A second column comprising similarly configured third
and a fourth blocks may now be constructed. The operation is the
same, with the third block positioned so that one of its sides is
adjacent to one of the sides of the first block and its groove
engages another rib of the already positioned second support beam.
The fourth block is then positioned on top of the third block in a
similar manner. That is, the fourth block is positioned so that one
of its sides is adjacent to one of the sides of the second block
and its groove engages another rib of the already positioned second
support beam. After the second column is erected, the third and
fourth blocks would be operatively connected to each other along
their respective free side by aligning the grooves of the
respective sides of the third and fourth blocks, and inserting at
least one rib of a third support beam into the aligned grooves and
seating it securely therein. After the third support beam is
seated, it is attached to the substructure. And so on.
[0103] The foregoing is considered as illustrative only of the
principles of the invention. Furthermore, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described. While the preferred
embodiment has been described, the details may be changed without
departing from the invention, which is defined by the claims.
* * * * *